How to Repair Flashlight Switch (Fix Tailcap Switch)

by Dhulfiqar in Circuits > LEDs

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How to Repair Flashlight Switch (Fix Tailcap Switch)

DIY How To Fix a Flashlight Switch ||  Torch Tail Cap Repair [Disassembly]
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Hello, Everyone!

in This Instructable, I will share with you How to Fix the Mechanical Switch in Flashlights (this method Should Work on Most flashlights except the Old Models like Maglite )

I will demonstrate the Repair on a Skywolfeye Zoomable Torch

ok, Let's Begin :)

Gently Pull the Rubber Cap

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*The Switch in this torch is Press-fitted, if The Switch in your Torch is Screwed in Then unscrew it first, Then pull the Rubber Cap

Use Something Thin But Not Sharp to Push the Plastic Housing Out of the Tailcap , Tap It Gently

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Pull the Switch From the Plastic Housing

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Measure the Resistance of the Switch to Make Sure That the Problem in the Flashlight Is Caused by the Switch Not From the Pill

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Use a Thin Object to Pry Open the Switch Through the Holes on the Sides

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if your Switch Does not Have Holes on the Sides Then use Something very thin

like a flat head screwdriver to wedge between the Side Crack of the switch (But Be careful not to cut yourself)

After Opening the Switch , Clean Its 3 Pins Very Well

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Use a metal File or Sand Paper to Remove any Rust from The Surface of the Conductors.

but don't file it too much, Just Scratch The Surface.

After Cleaning the Pins, Reassemble the Switch

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Measure the Resistance of the Switch

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Before the Repair The Resistance was 13 ohm, After the Repair, it Became in the Range of 0.01-0.1 OHM , Which means it became as good as new.

Put the Repaired Switch Back in the Plastic Housing

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Insert the Rubber Cap

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Insert the Plastic Housing , Then Tap It Lightly to Secure It in the Tailcap

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Connect the Tailcap to the Flashlight and Test It

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it Should Work :)

For More Details, Watch the Eembedded Video.

I hope This instructable was helpful to you


Thulfiqar Ali